Multi-ply carton



ETAL 3,4995% 7 March 10, 1970 F. H. FOLEY, JR,

MuL'rI-PLY CARTON 2 Sheets-Sheet 2 Filed March 17, 1967 m I OFS M M wm mL n A c .C mm M 58 W Vail mf g g g United States Patent York Filed Mar. 17, 1967, Ser. No. 624,031 Int. Cl. 365d /08 US. Cl. 229-37 13 Claims ABSTRACT OF THE DISCLOSURE A multi-ply carton having a loose outer ply imparting a hand-wrapped appearance to the carton. A pair of webs are adhesively secured to each other only along longitudinal edge portions outboard of a pair of fold lines. The webs are formed into carton blanks each of which includes a plurality of body panels inboard of the pair of fold lines and lap panels having oppositely directed extensions at opposite unsecured edge portions. One of the lap panels is adhesively secured in overlying relationship to an adjacent body panel and the outer plies of the lap panels are thereafter secured to each other. When formed into a carton the absence of any securement whatever of the plies to each other in the area of the body assures that the outer ply remains loose and imparts a hand-wrapped appearance to an automatically machine-formed carton.

It is convtntional to form pre-wrapped cartons by laminating a decorative outer wrapping to an inner and generally stronger paperboard blank. Such pre-wrapped cartons are quite commonly used for packaging individual bottles of liquor, lotion, perfume, and similar items which are customarily packaged in attractive packages having high consumer appeal. Unfortunately, conventionally produced pre-wrapped packages do not look hand-wrapped because the outer wrapping is not loose as would be the case if the carton were hand-wrapped as opposed to machine-wrapped. For this reason alone packagers who might normally desire to use such pre-wrapped cartons are hesitant to do so and consumers likewise ofttimes hesitate to purchase products packaged in prewrapped cartons because of the fake appearance thereof as compared to loosely hand-wrapped packages.

In keeping with the above it is a primary object of this invention to provide a novel pre-wrapped blank and carton, and a novel method of manufacturing the same whereby the outer wrapping of the carton is loose and imparts a hand-wrapped appearance thereto.

A further object of this invention is to provide a prewrapped carton blank having a pair of fold lines setting off therebetween body panels, the outer wrapping and inner ply of the carton blank being secured to each other only outboard of the fold lines, and the outer wrapping at opposite unsecured edge portions of the blank being adapted for securement to each other whereby the outer wrapping is maintained in a loose condition about a carton body formed from the blank thus imparting a handwrapped appearance to the carton.

Still another object of this invention is to provide a novel carton blank of the type heretofore set forth wherein at least one of the opposite unsecured edge portions includes a lap panel and oppositely directed extensions formed from the inner ply and the outer wrapping, the lap panel and its extensions being overfolded upon and adhesively secured to an adjacent panel of the blank, and the plies forming the lap extensions being secured to each other while the lap panels are wholly unconnected which augments the loose appearance of a carton formed therefrom.

Yet another object of this invention is to provide a novel method of forming a pre-wrapped blank adapted to be formed into a pre-wrapped carton by feeding a pair of generally superimposed webs along a pre-determined path, securing only longitudinal edge portions of the webs to each other, and forming the webs into generally polygonal blanks each of which has a pair of fold lines inboard of the secured edge portions whereby upon the folding of the blank into a carton and the securement of the outer plies of the unsecured edge portions to each other a body of the carton formed from the blank is provided with a loose hand-wrapped appearance.

Still another object of this invention is the provide a novel method of forming a blank in the manner heretofore described, and including the additional steps of feeding each blank with one of the secured edge portions leading and the other secured edge portion trailing whereby the lap extensions prevent air from entering between the plies of the blank, and folding each blank to bring one of the lap panels into adhesive contact with an adjacent body blank to present the outer ply thereof to its opposite unsecured edge portion during the folding of the blank to a tubular flattened configuration.

Another object of this invention is to provide a novel apparatus for forming the blank by the method described immediately heretofore.

With the above and other objects in view that will hereinafter appear, the nature of the invention will be more clearly understood by reference to the following detailed description, the appended claimed subject matter, and the several views illustrated in the accompanying drawings.

In the drawings:

FIGURE 1 is a highly schematic top perspective view of an apparatus for forming a multiply blank from which is formed a pre-wrapped carton, and illustrates the sequential steps in forming a tubular flattened blank from a pair of Webs.

FIGURE 2 is an enlarged sectional view taken generally along line 22 of FIGURE 1, andclearly illustrates the pair of webs being secured to each other only along longitudinal edge portions thereof.

FIGURE 3 is an enlarged sectional view taken generally along line 3-3 of FIGURE 1, and illustrates the cross-sectional configuration of the blank after having been provided with a plurality of fold lines.

FIGURE 4 is a top plan view with parts broken away for clarity of the planar blank of FIGURE 1 prior to being folded, and illustrates lap panels having oppositely directed extensions at each of a pair of opposite unsecured edge portions of the blank.

FIGURE 5 is a highly enlarged sectional view taken generally along line 55 of FIGURE 1, and illustrates the manner in which the blank is folded to bring the outer ply into overlying adhesive contact at the lap panels.

FIGURE 6 is an enlarged sectional view taken generally along line 66 of FIGURE 1, and illustrates a longitudinal seam formed between the exterior plies of the lap panels and extensions.

FIGURE 7 is a perspective view of a carton formed from the blank of FIGURE 4, and illustrates the loose nature of the outer ply in the area of the carton body.

FIGURE 8 is a sectional view taken generally along line 88 of FIGURE 7, and more clearly illustrates he loose nature of the outer wrapping.

An apparatus for forming a blank 10 (FIGURES 1 and 4) which is adapted to be set-up to form a pre-wrapped carton 15 (FIGURES 7 and 8) having a hand-wrapped appearance is fully illustrated in FIGURE 1 of the support respective rolls 23, 24 from which are drawn webs 25, 26, respectively. The web 25 is preferably a foil-paper laminate having an exterior decorated surface 27 which ultimately forms the exterior surface of the carton 15. The web 26 is preferably stronger, heavier paperboard or other similar foldable material. The webs 25, 26 are drawn from the respective rolls 23, 24 and moved from left-toright by a pair of driven rolls 30, 31 which are rotated by conventional means 29.

As the web 25 is fed from left-to-right lines of adhesive 32, 33 are applied to respective longitudinal edges 34, 35 of an upper surface'36 of the web 25 by adhesive applying means, generally designated by the reference character 37. The adhesive applying means 37 are a pair of conventional roller applicators 38, 40 which are suspended from a suitable support 41 forming a portion of the framework (not shown) of the apparatus 20.

As the webs 25, 26 are drawn between the bight of the rolls 30, 31 longitudinal edge portions 42, 43 of the web 26 are forced into intimate contact with the respective longitudinal edge portions 34, 35 of the web 25 thereby uniting the webs 25, 26 into a multi-pl or laminated web 45.

The laminated web 45 is then cut into the individual blanks 10 by a conventional shearing and fold-line forming apparatus 46 having a reciprocal cutting head 47 and a back-up plate 48.

Referring now to FIGURE 4 of the drawings, the blank 10 as it leaves the apparatus 46 includes a pair of plies 50, 51. The ply 51 of the blank 10 is formed from the material of the web 26 while the ply 50 is formed from the material of the web 25.

The blank 10 includes a pair of opposite edge portions 52, 53 at which the plies 50, 51 are secured to each other by the lines of adhesive 32, 33, respectively. At opposite longitudinal edge portions 54, 55 of the blank 10 the plies 50, 51 are completely free of each other between the lines of adhesive 32, 33.

A plurality of generally parallel fold lines 56 through 60 and a pair of fold lines 61, 62 normal to the fold lines 56 through 60 and inboard of the lines of adhesive 32, 33 set off a plurality of body-forming panels 63 through 66 and lap or glue panels 67, 68 adjacent the respective fold lines 56, 60. Closure panels 70 through 73 are joined to the respective panels 63 through 66 along the fold line 61 while closure panels 74 through 77 along the edge portion 52 are joined to the respective panels 63 through 66 along the fold line 62. In addition to the closure panels 70 through 77 joined to the associated body panels 63 through 66, the blank 10 further includes panels 78, 80, 81 and 82. The panels 78, 80 define oppositely di rected extensions of the lap panel 67 while the panels 81, 82 define oppositely directed extensions of the lap panel 68. It is to be noted that the portion of the plies 50, 51 at each of the lap panels 78, 80, 81 and 82 are adhesively joined to each other by the associated lines of adhesive 32, 33.

Referring again to FIGURE 1 of the draw ngs, after the blank 10 leaves the apparatus 46 it is transferred by means (not shown) to another conveyor 85 which feeds the blank from left-to-right with the edge portion 52 leading the trailing portion 53. It is also possible to feed the blank 10 with the edge portion 53 leading the edge portion 52. In either case due to the presence of the lap extensions 78, 80, 81 and 82 and the closure panels or flaps 70 through 77 of the plies 50, 51 which are adhesively secured to each other air cannot enter between the plies 50, 51 as would occur if either of the unsecured edge portions 54, 55 formed a leading edge of the conveyed blank. The blank 10 with the edge portion 52 leading is conveyed past a glue applying mechanism 86 which applies a line of adhesive A (FIGURE to the inner ply 51 across the lap panel extension 82, the lap panel 68 and the lap panel extension 81. A conventional folder 87 then folds the lap panel 68 and the lap panel extensions 81, 82 about the fold line 61 into overlying adhesive contact with the panels 66, 77 and 73, respectively. This overfolding of the lap panel 68 disposes the overlying portion of the outer ply 50 in an upwardly facing direction.

Thereafter another conventional folder 88 folds the panel 63 about the fold line 57 into generally overlying relationship with the panel 64. A strip of adhesive A (FIGURE 5) is then applied by a conventional adhesive-applying mechanism 90 to the outer ply 50 of the lap panel extensions 80, 78 and the lap panel 67. Thereafter the blank 10 proceeds through another folding mechanism 91 which folds the panel 66 about the fold line 59 to bring the outer ply 50 of the lap extensions 81, 82 and the lap panel 68 into contact with the adhesively coated outer surface of the outer ply 50 at the respective lap panel extensions 78, 80 and the lap panel 67.

The now folded, flattened tubular blank 10 can be unfolded as shown in FIGURE 8, either end closed by the closure flaps 70- through 73 or 74 through 77, an article packaged therein and the opposite end closed to complete the packaged carton 15. Since the outer ply or Wrapping 50 is not adhered in any manner to the inner ply 51 in the area between the fold lines 61, 62 the wrapping 50 is and appears loose about the entire body of 5 the carton 15 defined by the panels 63 through 66. This is true also in the area of the longitudinal seam (unnumbered) defined by the lap panels 67, 68, the inner and outer plies of which are not secured to each other. In the area of this scam it is only the opposing portions of the outer ply 50 which are adhesively united by the strip of adhesive A. Therefore, the exterior wrapper 50 is entirely free of the inner ply 51 at the body of the carton 15 and a true hand-Wrapped appearance is imparted to the carton even though the same is automatically machine-made.

While preferred forms and arrangement of parts have been shown in illustrating the invention, it is to be clearly understood that various changes in details and arrangement of parts may be made without departing from the spirit and scope of the invention as defined in the appended claimed subject matter.

We claim:

1. A carton blank comprising a pair of generally planar sheet material members in overlying relationship with each other, said blank having spaced side and end edge portions, a plurality of first fold lines disposed generally parallel to said side edge portions in part dividing said blank into a plurality of body panels, a plurality of second fold lines disposed generally normal to said side edge portions in part dividing said blank into a plurality of closure flaps at each of said end edge portions, means securing said members to each other only outboard of said second fold lines, and said blank being devoid of securing means between the body panels of said members whereby said blank can be folded to form a carton in which one of the sheet material members defines a loose outer wrapper of a carton body formed by said panels thus imparting a hand-wrapped appearance to the carton.

2. The carton blank as defined in claim 1 wherein said members include overlying lap panels adjacent one of said body panels at one of said side edge portions, said lap panels each having a pair of oppositely directed extensions positioned outboard of said second fold lines, means securing the extensions of one of said members to the extensions of the other of said members outboard of said second fold lines, and the lap panels of said members being devoid of securing means therebetween.

3. The carton blank as defined in claim 2 wherein said lap panels are in overlapped relationship to an adjacent body panel, and means are provided for securing one of said lap panels in overlapped relationship to said adjacent body panel.

4. The carton blank as defined in claim 2 wherein said members include other overlying lap panels adjacent another of said body panels at the other of said side edge portions, said last-mentioned lap panels each having a pair of oppositely directed extensions positioned outboard of said second fold lines, means securing the extension of one of said members to the last-mentioned extensions of the other of said members outboard of said second fold lines, and the last-mentioned lap panels of said members being devoid of securing means.

5. The carton blank as defined in claim 4 wherein the lap panels adjacent at least one of said side edge portions are in overlapped relationship to an adjacent body panel, and means are provided for securing one of said last-mentioned lap panels in overlapped relationship to said last-mentioned adjacent body panels.

6. A carton comprising an inner member and an outer wrapper, said carton having a body portion defined between a pair of axially spaced circumferential fold lines, closure means joined to said body portion along said fold lines, adhesive means securing the closure means of said inner member and said outer wrapper to each other, and said body portion being devoid of securing means between the inner member and the outer wrapper thereby imparting a loose hand-wrapped appearance to the carton body portion.

7. The carton as defined in claim 6 wherein said inner member and outer wrapper include overlying lap panels along an axial edge portion of said body portion, said lap panels each having joined thereto a pair of oppositely axially directed extensions positioned axially outboard of said body portion, means securing the extensions of said inner member to overlying extensions of said outer wrapper, and the lap panels being devoid of securing means and completely unconnected from each other.

8. The carton as defined in claim 7 wherein the lap panel of said inner member is overfolded upon and secured to an adjacent portion of said inner member, and adhesive means for securing a portion of the outer wrapper adjacent said lap panel to a portion of the outer wrapper remote from said lap panel thereby defining a longitudinal seam of said carton.

9. The carton as defined in claim 7 wherein the lap panel of said inner member is overfolded upon and secured to an adjacent portion of said inner member, said inner member and outer wrapper include other overlying lap panels along another axial edge portion of said body portion, said other lap panels each having joined thereto a pair of oppositely axially directed extensions positioned axially outboard of said body portion, means securing said last-mentioned extensions of said inner member to overlying extensions of said outer wrapper, and means securing the outer wrapper to itself at the lap panels.

10. The carton blank is defined in claim 1 wherein one of said sheet material members is an outer wrapper and the other of said sheet material members is an inner container-forming member, said wrapper and said contamer-forming member include overlying lap panels adjacent one of said body panels at one of said side edge portions, the lap panel of said container-forming member is folded upon an adjacent body panel of said containerfor-ming member, and means securing said last-mentioned lap panel in its folded position.

11. The carton blank as defined in claim 10 wherein said lap panels each have a pair of oppositely directed extensions positioned outboard of said second fold lines, and said last-mentioned means is adhesive securing said lap extensions to each other and to adjacent ones of said closure flaps.

12. The carton as defined in claim 6 wherein said inner member and said outer wrapper include overlying lap panels secured to each other by adhesive.

13. The carton as defined in claim 6 wherein said inner member and said outer Wrapper include overlying lap panels along each of a pair of axially extending edge portions of the body portion, adhesive securing the lap panels of the inner member to each other, and the overlying lap panels of the inner member and outer wrapper being devoid of adhesive therebetween.

References Cited UNITED STATES PATENTS 1,775,027 9/1930 Hartmann 229-14 2,423,804 7/ 1947 Waters 229-14 X 2,425,043 8/ 1947 Moore 22914 2,479,456 8/1949 Arthur 22914 3,257,068 6/1966 Wright 22987 3,343,750 9/1967 Desmond et al 22987 DAVIS T. MOORHEAD, Primary Examiner U.S. Cl. X.R. 22987 

